Harley Davidson 2005 touring models. Service repair manual — page 4

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c. Check belt deflection. Apply 10 lbs. (4.5 kg) of force

at the midpoint of the bottom belt strand. Belt

CAUTION

deflection should be within the range specified in

Verify that the heat shields do not contact the vehicle

Table 2-3.

frame or any mounted components. Contact will cancel

d. If belt is still too tight, repeat steps 11(a) through

the effect of the rubber isolation mounts and transmit

11(c). If belt is now too loose, move to step 10.

vibration to the rider via the vehicle frame.

Remove bungee cord from muffler.

12. Holding weld nut on left side of axle, tighten cone nut on

right side to 95-105 ft-lbs (128.8-142.4 Nm).

Right Side

NOTE

Slide new TORCA clamp onto free end of rear

If the axle moves during tightening of the cone nut, then the

belt deflection procedure must be restarted.

header pipe.

Using a bungee cord, tie muffler to lower saddlebag

13. Recheck belt deflection to verify that it is still within spec-

support rail. Install muffler on rear header pipe.

ification.

Place TORCA clamp into position between rear

If the belt deflection is not within specification, loosen

header pipe and muffler.

cone nut and then snug to 15-20 ft-lbs (20-27 Nm)

Tighten the two bolts (with lockwashers) to fasten

before returning to step 10.

the muffler to the lower saddlebag support rail.

14. With the flat side out, install new E-clip in groove on right

side of axle.

CAUTION

15. Install both mufflers as follows:

Verify that the exhaust pipes do not contact the vehicle

NOTE

frame or any mounted components. Contact will cancel

the effect of the rubber isolation mounts and transmit

TORCA muffler clamps have eliminated the need for silicone

vibration to the rider via the vehicle frame.

or graphite tape during assembly. To ensure sealing integrity

of muffler clamps and prevent the possibility of leakage, Har-

Verify that exhaust pipes are in alignment and do

ley-Davidson recommends that TORCA clamp assemblies be

not contact the vehicle frame or mounted compo-

discarded and replaced each time they are removed.

nents.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Nm).

Left Side

Open worm drive clamps and install heat shield on

a. Slide new TORCA clamp onto free end of crossover

rear header pipe. Position clamp so that screw is on

pipe.

the outboard side in the most accessible position.

b. Using a bungee cord, tie muffler to lower saddlebag

support rail. Install muffler on crossover pipe. Place

CAUTION

TORCA clamp into position between crossover and

muffler.

Verify that the heat shields do not contact the vehicle

frame or any mounted components. Contact will cancel

c. Tighten the two bolts (with lockwashers) to fasten

the effect of the rubber isolation mounts and transmit

the muffler to the lower saddlebag support rail.

vibration to the rider via the vehicle frame.

g. Remove bungee cord from muffler.

CAUTION

Verify that the exhaust pipes do not contact the vehicle

frame or any mounted components. Contact will cancel

1WARNING

the effect of the rubber isolation mounts and transmit

After installation of caliper and BEFORE moving motor-

vibration to the rider via the vehicle frame.

cycle, pump rear brake pedal until pistons push pads

d. Verify that exhaust pipes are in alignment and do

against the brake disc. If fluid pressure is not pumped

not contact the vehicle frame or mounted compo-

up, the rear brake will not be available the first time it is

nents.

used, a situation that could result in death or serious

injury.

e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81

Nm).

16. Depress rear brake pedal several times to set brake

pads to proper operating position within caliper.

Open worm drive clamps and install heat shield on

crossover pipe. Position clamp so that screw is on

17. Install saddlebags. See Section

2.25 SADDLEBAG,

the outboard side in the most accessible position.

INSTALLATION.

2-16

2005 Touring: Chassis

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CHECKING RIM RUNOUT

2.5

INSPECTION

f1379x2x

Check wheels for lateral and radial runout before installing a

new tire or tube.

1. Install truing arbor in wheel hub and place wheel in

WHEEL TRUING STAND, Part No. HD-99500-80.

2. See Figure 2-15. To check rim lateral runout, place a

gauge rod or dial indicator near the rim bead. If lateral

runout exceeds 0.040 inch (1.02 mm), replace the wheel

if cast. Retrue the wheel if laced.

3. See Figure 2-16. Check the rim radial runout as shown.

If radial runout exceeds 0.030 inch (0.76 mm), replace

the wheel if cast. Retrue the wheel if laced.

Radial

NOTE

Runout

Rim lateral and radial runout is adjustable on laced wheels.

See Section 2.7 TRUING LACED WHEEL.

Gauge

f1378x2x

Figure 2-16. Checking Rim Radial Runout

If working with a laced wheel, proceed to Section 2.7

TRUING LACED WHEEL to check the wheel offset

dimension.

Lateral

Runout

Gauge

Figure 2-15. Checking Rim Lateral Runout

2005 Touring: Chassis

2-17

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WHEEL LACING-16 INCH RIM

2.6

GENERAL

WHEEL LACING

If front wheel, place the hub on a table with the wider

CAUTION

flange side up. If rear wheel, place hub so that brake

disc side is up. Insert a spoke in each hole of the lower

While the steel laced and chrome aluminum laced profile

row as shown below. Angle the spokes in a clockwise

wheels use the same hub, exercise caution to avoid mix-

direction.

ing or interchanging any other parts. Do not install the

chrome plated spokes and/or spoke nipples on a steel

rim. Likewise, do not install the zinc plated spokes and/

f1150d2x

or spoke nipples on a chrome plated rim. Mixing or inter-

changing parts can result in wheel damage.

The spoke nipple fittings use a TORX style fastener and

requires a special T-30 I.P. (TORX Plus) driver (HD-42135)

for removal and installation. See A of Figure 2-17. Use of a

standard T-30 TORX bit will result in nipple damage.

Figure 2-18.

Center rim over hub with the valve stem side up. Using

any lower row spoke, place the first spoke into the rim

f1150a2x

hole to the left of the valve stem hole on the upper half of

the rim centerline.

Narrow Flange

Belt Sprocket Side

Wide Flange

First

Lower Row Spoke

Valve Stem Hole

f1150b2x

Valve Stem Flat

Tombstone Shaped

on Steel Rim

f1150c2x

f1150e2x

Figure 2-17. Spoke Nipple, Hub and Rim

Figure 2-19.

2-18

2005 Touring: Chassis

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3. Install the rest of the lower row spokes in every fourth

Install the nine remaining upper row spokes into every

hole.

fourth hole remaining above the rim centerline.

f1150f2x

f1150h2x

Figure 2-20.

Figure 2-22.

4. Place the first upper row spoke into the hub as shown

Turn the wheel over. Place any lower row spoke into the

below. Angle the spoke counterclockwise crossing four

hub. Angle the spoke clockwise and place into rim hole

lower row spokes. The spoke must enter the hole to the

angled to accept it.

left of the valve stem hole.

First

Upper Row Spoke

Lower Row Spoke

f1150g2x

f1150i2x

Figure 2-21.

Figure 2-23.

2005 Touring: Chassis

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Angled clockwise, place the nine remaining lower row

9. Install the nine remaining upper row spokes into hub and

spokes into hub and rim.

rim.

f1150j2x

f1150l2x

Figure 2-24.

Figure 2-26.

Insert any upper row spoke into the hub and angle spoke

counterclockwise. Place spoke into appropriate rim hole

CAUTION

crossing four lower row spokes.

The hub is made of aluminum alloy and should not be

clamped in a vise or gripped with pliers, or the hub mate-

First

rial may be damaged.

Upper Row Spoke

10. Verify that wheel is true. See Section

2.7 TRUING

LACED WHEEL for truing procedure and spoke torque

specification.

SPOKE TIGHTNESS

See Section 1.6 WHEEL SPOKES.

f1150k2x

Figure 2-25.

2-20

2005 Touring: Chassis

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TRUING LACED WHEEL

2.7

PROCEDURE

1. Divide the wheel spokes into ten groups of four and

mark the center of each group with a piece of tape. The

groups should be directly across from one another and

approximately 90^ο apart. Tighten the spokes in these

four groups finger tight, leaving all others loose.

2. See Figure 2-28. Install truing arbor in wheel hub and

place wheel in WHEEL TRUING STAND, Part No. HD-

99500-80. Tighten arbor nuts so hub will turn on its bear-

ings.

3. Lay a straightedge across the hub brake disc flange

(valve stem side of dual disc front wheel) and one of the

marked spoke groups. Measure the distance from the

straightedge to the edge of the rim as shown in Figure 2-

27. Be sure to subtract the thickness of the straightedge.

f1155b2x

See Figure 2-29. The offset dimension must be as fol-

lows:

Figure 2-27. Checking Steel Laced Hub Offset Dimension

Table 2-4. Offset Dimensions

f1379x2x

RIM TYPE

RIM SIZE

IN.

MM.

Steel Laced

Front

1.555-1.575

39.5-40.0

Rear

1.472-1.492

37.4-37.9

Chrome Aluminum Laced Profile

Front

1.270-1.290

32.3-32.8

Rear

1.190-1.210

30.2-30.7

If the dimension is not correct, tighten the four spokes

accordingly. Use the special T-30 I.P. (TORX Plus) driver

(HD-42135). For example, If the measurement on the

right rim edge side is less than it should be, loosen the

Radial

two spokes attached to the hub right side and tighten the

Runout

two spokes attached to the hub left side. Turn all four

spokes an equal number of turns until offset dimension

is correct.

Gauge

CAUTION

Always loosen the appropriate spokes before tightening

the other two. Reversing this procedure will cause the

rim to become out-of-round.

Figure 2-28. Truing Steel Laced Rim Radially

4. Repeat Step 3 for all four groups on the wheel.

5. See Figure 2-28. After rim has been trued sideways it

must be checked and trued radially. Adjust truing stand

gauge to the rim's tire bead seat as shown. The rim

should be trued within 1/32 inch (0.79 mm).

2005 Touring: Chassis

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HOME

Spin the rim slowly. If the rim contacts the gauge on or

near a marked group of spokes, loosen the spokes in the

Steel Laced Rim

marked group on the opposite side of the rim. Now

tighten the spokes in the group where the rim makes

contact. Loosen and tighten spokes an equal number of

turns.

If the rim contacts the gauge between two marked

groups, loosen the spokes in both opposite groups and

tighten the spoke groups on the side of the rim that

makes contact.

When the wheel is centered and trued, start at the valve

stem hole and tighten the rest of the spoke nipples one

turn at a time until they are snug. Repeat step tightening

each spoke nipple to 40-50 in-lbs (4.5-5.6 Nm).

Offset:

1WARNING

1.472-1.492 in.

Do not tighten spokes too tight, or nipples may be drawn

through rim, or hub flanges may be distorted. If spokes

are left too loose, they will continue to loosen when

wheel is put into service. This could adversely affect

handling, or cause spoke breakage, possibly leading to

loss of vehicle control, which could result in death or

serious injury.

File or grind off ends of spokes protruding through nip-

ples to prevent puncturing tube when tire is mounted.

10. Check the rim lateral and radial runout as described

under Section 2.5 CHECKING RIM RUNOUT.

NOTE

Offset:

After installation of front wheel, visually check the relation-

1.190-1.210 in.

ship of the front wheel to the fork fender bosses. The front

wheel should be approximately centered between the

bosses.

Chrome Aluminum

Laced Profile Rim

f2334x2x

Figure 2-29. Laced Hub Offset Dimension (16 Inch Rear)

2-22

2005 Touring: Chassis

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TIRES AND TUBES

2.8

GENERAL

1634

Tires should be inspected for punctures, cuts, breaks and

wear at least weekly.

Whenever a tube type tire is replaced, the tube should also

be replaced. Inner tubes should be patched only as an emer-

gency measure. Replace a damaged tube as soon as possi-

ble. Inner tubes must be used on all Harley-Davidson laced

wheels.

1WARNING

Excessively worn tires are more susceptible to penetra-

tions. Always remove tires from service before they

reach the tread wear indicator bars, which indicates that

1/32 inch (0.79 mm) tread pattern depth remains. Worn/

unworn tire combinations and worn tires used in wet

conditions can ad-versely affect handling and lead to

loss of vehicle control, which could result in death or

serious injury.

Figure 2-30. Starting Bead Off Rim

1WARNING

Tubeless tires may be repaired in the tread area only and

Loosen both tire beads from rim flange. See Figure 2-30.

then the puncture must be 1/4 inch (6.4 mm) or smaller.

In most cases, a bead breaker machine will be required

Never repair a tire with less than 1/16 inch (1.6 mm) tread

to loosen the bead from the rim.

depth. All repairs must be made from inside the tire. Use

of faulty or defective tires can adversely affect handling

Using tire tools (not sharp instruments), and RIM PRO-

and lead to loss of vehicle control, which could result in

TECTORS, Part No. HD-01289, start upper bead over

death or serious injury.

edge of rim at valve. Do not use excessive force when

starting bead over rim. Bead wires may be damaged

NOTE

ruining the tire. Repeat all around rim until first bead is

Acceptable repair methods include a patch and plug combi-

over rim. Remove the tube.

nation, chemical or hot vulcanizing patches or head-type

plugs.

NOTE

When repairing tubeless tires, use TIRE SPREADER, Part

is not necessary to use tools to remove tubeless tires.

No. HD-21000 to spread the tire sidewalls.

Make sure beads are well lubricated before removing from

rim.

1WARNING

Push lower bead into rim well on one side and insert tire

tool underneath bead from opposite side. Pry bead over

Always check both tire sidewalls for arrows indicating

rim edge. Remove tire from rim.

proper forward tire rotation. Some tires require different

tire rotation depending on whether tire is used on front

NOTE

or rear wheel. Improper mounting can result in poor tire

It is not always necessary to completely remove tire from rim.

mileage. In wet weather, improper mounting can ad-

Removing one side allows the tube to be replaced and allows

versely affect handling and lead to loss of vehicle con-

for inspection of tire.

trol, which could result in death or serious injury.

CLEANING AND INSPECTION

REMOVAL

1. Remove wheel from motorcycle. Let the air out of the

Clean the inside of tire, rim and tube. If rim is dirty or

tube or tire.

rusty, clean with a stiff wire brush.

2005 Touring: Chassis

2-23

HOME

1635

Indicator

Ring

Figure 2-31. Snap-in Tubeless Tire Valves

Inspect the tire and tube for wear.

INSTALLATION

Figure 2-32. Starting Bead on Rim

1636

1WARNING

Use the correct inner tube and tire. See TIRE DATA in

SPECIFICATIONS. Use of incorrect tires or tubes can

adversely affect handling or result in tire failure, which

could result in death or serious injury.

1WARNING

Do not interchange tire valves from one type to another.

Always replace valves with the same type as originally

furnished, either the threaded valve stem or snap-in

type. The rim configuration is designed to fit one type

only. Use of the wrong valve can lead to tire failure,

which could result in death or serious injury.

Figure 2-33. Starting Second Bead on Rim

1. On tubeless wheels, damaged or leaking valves must be

replaced. To replace a snap-in type valve proceed as fol-

lows:

1WARNING

a. See Figure 2-31. Moisten the valve with water and

insert valve stem through rim hole.

Aftermarket valve caps that are heavier than the original

equipment cap may have clearance at slow speeds, but

b. Thread plug tool on valve stem and pull valve

at high speed the valve/cap will be moved outward by

through rim until all of the indicator ring is visible.

centrifugal force. This movement could cause the valve/

cap to strike adjacent components, damage the valve

and cause rapid tire deflation. Rapid tire deflation can

1WARNING

cause loss of vehicle control, which could result in death

Only install original equipment tire valves and valve

or serious injury.

caps. A valve, or valve and cap combination, that is too

long may strike adjacent components, damage the valve

On laced wheels, install a rim strip into the rim well.

and cause rapid tire deflation. Rapid tire deflation can

Make sure no spokes protrude through nipples and be

cause loss of vehicle control, which could result in death

sure to align the valve stem hole in rim strip with hole in

or serious injury.

rim.

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2005 Touring: Chassis

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Thoroughly lubricate the rim flanges and both beads of

the tire with tire lubricant. Install RIM PROTECTORS,

f1386b2x

Part No. HD-01289 to prevent scarring rims.

See Figure 2-32. Starting at the valve stem, start the first

bead into the rim well. Work the bead on as far as possi-

ble by hand. Use the tire tool to pry the remaining bead

over the rim flange. If tire has colored dot on sidewall, it

is a balance mark and should be located next to valve

stem hole.

Inflate tube just enough to round it out. Lubricate thor-

oughly 360˚ around the tube base. Insert tube in tire with

valve stem in hole.

See Figure 2-33. Starting 180˚ from valve stem, start the

Gauge

second bead onto the rim. Work the bead onto the rim

with tire tools, working toward valve in both directions.

Remove the valve core from the rim hole before prying

the remaining bead over the rim flange.

Tire Radial Runout

Make sure inner tube valve stem moves in and out freely,

then inflate the tire to recommended pressure to seat the

bead. See TIRE DATA at the beginning of this section.

Figure 2-34. Checking Tire Radial Runout

Then deflate tire to allow inner tube to smooth out.

Inflate again to recommended pressure to seat the

bead.

Use the BEAD EXPANDER (Part No. HD-28700) to seat

Tire Lateral

beads on tubeless tires.

Runout

1WARNING

Do not inflate tire over 40 psi (2.8 bars) to seat beads.

Inflating tire beyond this point can cause the tire rim

assembly to burst, which could result in death or serious

injury. If the beads fail to seat, deflate and relubricate the

bead and rim. Reinflate to seat beads, but do not exceed

40 psi (2.8 bars).

Gauge

CAUTION

When mounting tire and tube on the rim, use extreme

care so the inner tube is not pinched.

f1386a2x

Figure 2-35. Checking Tire Lateral Runout

Checking Tire Radial Runout

1. Check runout by turning wheel on axle, measuring

amount of radial displacement from a fixed point near

Checking Tire Lateral Runout

the tire. See Figure 2-34.

Check runout by turning wheel on axle, measuring tread

2. Tire tread runout should be no more than 0.090 inch

runout. See Figure 2-35.

(2.28 mm) If tire tread runout exceeds this specification,

remove tire from rim and check rim runout to see if rim is

Tire tread runout should be no more than 0.080 inch

at fault. (See Section 2.5 CHECKING RIM RUNOUT).

(2.03 mm). If tire tread runout exceeds this specifica-

tion, remove tire from rim and check rim bead runout to

NOTE

see if rim is at fault (see Section 2.5 CHECKING RIM

Make sure bead is properly seated on rim. Deflate and reseat

RUNOUT).

tire if necessary.

NOTE

3. If rim runout is less than 1/32 inch (0.79 mm), tire is at

fault and should be replaced. If rim runout exceeds this

Make sure bead is properly seated on rim. Deflate and reseat

specification, correct by replacing cast wheel or truing

tire if necessary.

laced wheel.

2005 Touring: Chassis

2-25

HOME

If rim bead runout is less than 1/32 inch (0.79 mm), tire

NOTE

is at fault and should be replaced. If rim bead runout

If 1 oz. (28g) or more weight must be added at one location,

exceeds this specification, correct by replacing cast

split the amount so that half is applied to each side of the rim.

wheel or truing laced wheel.

2. Remove paper backing from weight and apply three

drops of Loctite® SUPERBONDER® 420 to the adhe-

Wheel Balancing

sive side of the weight. Place the weight on rim, press

firmly in place and hold for 10 seconds. Full adhesive

Wheel balancing is recommended to improve handling and

cure takes 8 hours.

reduce vibration, especially at high road speeds. Cast alumi-

num wheels require special self-adhesive weights. Gold

3. In most cases, static balancing using WHEEL TRUING

Color - 1 oz. (28g) weight, 1/2 oz. (14g) weight, Silver Color

STAND, Part No. HD-99500-80, will produce satisfactory

1/2 oz. (14g) and 1/4 oz. (7g), and Black 1/4 oz. (7g) weight.

results. However, dynamic balancing, utilizing a wheel

spinner, should be used to produce finer tolerances for

Laced wheels use balance weights which press over the

best high and low speed handling characteristics. Follow

spoke nipples. 1 oz. (28g), 3/4 oz. (21g) and 1/2 oz. (14g)

the instructions supplied with the balance machine you

weights are available.

are using. Wheels should be balanced to within 1/2 oz.

Self adhesive wheel weights should be applied to the flat

(14g) at 60 mph (96 km/h). The maximum permissible

surface of the rim. Make sure that area of application is

weight to accomplish balance is 3-1/2 oz. (99g) total.

completely clean, dry and free of oil and grease.

2-26

2005 Touring: Chassis

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VEHICLE ALIGNMENT

2.9

1WARNING

Vehicle alignment is very important to ensure proper

handling and vibration control. Follow this procedure

carefully and in the sequence given. Failure to do so may

lead to loss of vehicle control, which could result in

death or serious injury.

METHOD A

f2117x2x

NOTE

Figure 2-36. Vehicle Alignment Tool

Use this procedure to realign the powertrain to the frame

(Part No. HD-46247)

whenever major disassembly or engine replacement occurs.

For acceptable results, a careful inspection should be

f2118x2x

performed (wheel and tire runout, laced wheel offset, rubber

mount condition, etc.) to ensure that it is conducted with

serviceable components. See INSPECTION for more infor-

Alignment

mation.

Fixture

Place the motorcycle on a hydraulic center stand or

place blocking under the frame to support the vehicle

and lift the rear wheel off the ground. Be sure the motor-

cycle is positioned as level as possible.

Remove socket screw with lockwasher to remove left

passenger footboard from rear swingarm bracket.

Tighten both rear swingarm bracket bolts to 34-42 ft-lbs

Pilot

Alignment

(46-57 Nm). Repeat step on right side of motorcycle.

Screw

Remove the decorative chrome plug from both rear

swingarm brackets. While holding the left side pivot shaft

Figure 2-37. Install Vehicle Alignment Tool (Left Side)

locknut, tighten the right side locknut to 40-45 ft-lbs (54-

61 Nm). Then hold the right side pivot shaft locknut and

tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).

c. Loosen both top stabilizer link jam nuts.

Verify that belt deflection is within specification and that

d. Remove the top stabilizer link eyelet to top engine

adjuster cams are tight against rear swingarm weld

mounting bracket bolt. See B of Figure 2-38.

nubs. Holding weld nut on left side of axle, tighten cone

8. Front Engine Mount:

nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).

a. Remove flange locknuts from studs on lower frame

Remove seat. See Section 2.24 SEAT, REMOVAL.

crossmember. Remove voltage regulator from studs

Partially remove fuel tank to gain access to top engine

and allow to hang by cables at front of motorcycle.

mounting bracket and stabilizer link. See Section 4.7

b. Tighten two engine to front engine mounting bracket

FUEL TANK (CARBURETED), PARTIAL REMOVAL,

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-

FLHT/C, or FLHR/S. For fuel injected models, see Sec-

38.

tion

9.4 FUEL TANK (FUEL INJECTED), PARTIAL

REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

c. Tighten front stabilizer link eyelet bolt to block on

front engine mounting bracket to 18-22 ft-lbs (24-30

Top Engine Mount:

Nm). See E of Figure 2-38.

a. On left side of motorcycle, tighten the two top

d. Loosen both front stabilizer link jam nuts.

engine mounting bracket to front and rear cylinder

head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-

e. Remove front stabilizer link eyelet to frame weld-

ure 2-38.

ment bolt. See D of Figure 2-38.

b. Moving to right side of motorcycle, tighten the top

Remove the center front engine mounting bracket to

stabilizer link eyelet to frame weldment bolt to 18-22

rubber mount bolt (with washers and nut). See F of

ft-lbs (24-30 Nm). See C of Figure 2-38.

Figure 2-38.

2005 Touring: Chassis

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HOME

LEFT SIDE

RIGHT SIDE

Top Stabilizer Link and Engine Mounting Bracket

f2181x2x

f2111x2x

Jam Nut

Front

Stabilizer Link

Front Engine

Mounting Bracket

f1303x2x

Front Stabilizer Link and Engine Mounting Bracket

Top

Bottom

A Top Engine Mounting Bracket to Cylinder Heads

D Eyelet to Frame Weldment

B Eyelet to Top Engine Mounting Bracket

E Eyelet to Front Engine Mounting Bracket

C Eyelet to Frame Weldment

F Front Engine Mounting Bracket to Rubber Mount

G Front Engine Mount to Frame Crossmember

H Engine to Front Engine Mounting Bracket

Figure 2-38. Engine Mounting Bracket Bolts

Obtain Vehicle Alignment Tool (HD-46247). See Figure

a. Back off alignment screws and pilot so that no con-

2-36. Proceed as follows:

tact is made with pivot shaft during initial installa-

tion.

2-28

2005 Touring: Chassis

HOME

b. Position alignment fixture so that pilot begins to

b. If centering or relaxation of the mount is required,

engage hole in rear swingarm bracket and then

proceed as follows:

start 5/16 allen head screw (with flat washer) into

•

Loosen the two front engine mount to frame cross-

lower hole of passenger footboard mount. Leave fix-

member bolts. See G of Figure 2-38.

ture loosely installed. Repeat step on other side of

motorcycle.

•

Push on the rubber mount to center it with the thru

bolt hole in the mounting plate. It may be necessary

NOTE

to bounce or wiggle the engine to unload any

Alignment fixtures are stamped L(eft) and R(ight) for easy

binding of the rubber mount on the mounting plate.

identification. When installing alignment fixture on right side

of motorcycle, first remove hex screw to free brake hose P-

•

After the mount is centered, tighten the two front

clamp from rear swingarm bracket. The relief in right side fix-

engine mount to frame crossmember bolts to 15-20

ture accommodates hex screw boss.

ft-lbs (20-27 Nm). See G of Figure 2-38.

c. Holding alignment fixture tight against rear swing-

•

Install center front engine mounting bracket to rub-

arm bracket, use knurling to rotate pilot until it bot-

ber mount bolt (with washers and nut) and tighten to

toms in rear swingarm bracket. Without disturbing

15-20 ft-lbs (20-27 Nm). See F of Figure 2-38.

setting of pilot, tighten allen head screw to passen-

ger footboard mount to 18-22 ft-lbs (24-30 Nm).

15.

Slide voltage regulator over studs on lower frame cross-

Repeat step on other side of motorcycle.

member at front of vehicle. Install flange locknuts on

d. Hand turn alignment screw until it bottoms against

studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).

end of pivot shaft. Repeat step on other side of

16.

Install fuel tank. For carbureted models, see Section 4.7

motorcycle.

FUEL TANK (CARBURETED), INSTALLATION (AFTER

e. Tighten alignment screw to 60-80 in-lbs (6.8-9.0

PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel

Nm). Repeat step on other side of motorcycle. See

injected models, see Section 9.4 FUEL TANK (FUEL

Figure 2-37.

INJECTED), INSTALLATION

(AFTER PARTIAL

REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

10.

Adjust each stabilizer link as follows:

17.

Verify minimum clearance between the powertrain and

a. Install bolts removed under steps 7(d) and 8(e), and

the following frame mounted components:

using the center hex to maintain equal thread

a. Top Engine/Horn Mounting Bracket to Fuel Tank:

engagement at both eyelets, adjust stabilizer links

0.328 inch (8.3 mm).

so that bolts thread in without any stress or engine

movement. See B and D of Figure 2-38.

b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).

b. Alternately tighten bolts to 18-22 ft-lbs (24-30 Nm).

c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5

mm).

c. Holding the stabilizer link adjuster and mounting

eyelets to prevent movement or binding, tighten jam

d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4

nuts on top and front stabilizer links.

mm).

e. Top Stabilizer Link to Induction Module: 0.375 inch

11.

Remove vehicle alignment tool from rear swingarm

(9.5 mm).

brackets.

Front Stabilizer Link to Voltage Regulator: 0.375

12.

Snap the chrome plugs back into the rear swingarm

inch (9.5 mm).

brackets.

g. Inner Primary Chaincase to Lower Frame Tube:

13.

Install socket screw with lockwasher to fasten passenger

0.187 inch (4.8 mm).

footboard to rear swingarm bracket. Tighten screw to 15-

18 ft-lbs

(20-24 Nm). Repeat step on other side of

h. Exhaust Crossover Pipe to Primary Housing: 0.125

motorcycle.

inch (3.2 mm).

14.

Verify that front rubber mount is centered under the front

Tire to Rear Fender: 0.100 inch (2.5 mm).

mounting plate bolt hole and has not been bound by the

Perform the procedure under Method B to trouble-

plate dragging across the isolator.

shoot clearance problems and to identify offending

a. If the front rubber mount is centered and free of

component(s).

binding, proceed as follows:

18.

Install seat. See Section 2.24 SEAT, INSTALLATION.

•

Tighten the two front engine mount to frame cross-

member bolts to 15-20 ft-lbs (20-27 Nm). See G of

19.

Test ride the motorcycle.

Figure 2-38.

NOTE

•

Install center front engine mounting bracket to rub-

Vehicle leads that require more than 2-lbs pull to correct

ber mount bolt (with washers and nut) and tighten to

need further diagnosis. Perform the procedure under Method

15-20 ft-lbs (20-27 Nm). See F of Figure 2-38.

B in this section.

2005 Touring: Chassis

2-29

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c. Tighten front stabilizer link eyelet to frame weldment

METHOD B

bolt to 18-22 ft-lbs (24-30 Nm). See D of Figure 2-

38.

NOTE

d. Tighten front stabilizer link eyelet bolt to block on

Use this procedure to determine the cause of vehicle mis-

front engine mounting bracket to 18-22 ft-lbs (24-30

alignment and to locate clearance problems, or as an

Nm). See E of Figure 2-38.

alternative to use of the Vehicle Alignment Tool (HD-46247)

e. Remove the center front engine mounting bracket to

described under Method A. For acceptable results, a careful

rubber mount bolt (with washers and nut). See F of

inspection should be performed (wheel and tire runout, laced

Figure 2-38.

wheel offset, rubber mount condition, etc.) to ensure that it is

conducted with serviceable components. See INSPECTION

To verify alignment, install alignment bars or other suit-

for more information.

able device on both the left and right side of motorcycle.

Proceed as follows:

Place the motorcycle on a hydraulic center stand or

place blocking under the frame to support the vehicle

NOTE

and lift the rear wheel off the ground. Be sure the motor-

If the front tire is wider than the rear, then the alignment bars

cycle is positioned as level as possible.

must either be shimmed out equally at the points of contact

Remove socket screw with lockwasher to remove left

on the rear tire, notched at the front to clear the front tire, or

passenger footboard from rear swingarm bracket.

attached to the front tire with all measurements performed at

Tighten both rear swingarm bracket bolts to 34-42 ft-lbs

the rear. For explanatory purposes, the following procedure

(46-57 Nm). Repeat step on right side of motorcycle.

assumes the alignment bars are secured to the rear tire.

Remove the decorative chrome plug from both rear

swingarm brackets. While holding the left side pivot shaft

a. Place a set of straightedges on both the left and

locknut, tighten the right side locknut to 40-45 ft-lbs (54-

right sides of the motorcycle alongside the front and

61 Nm). Then hold the right side pivot shaft locknut and

rear tires.

tighten the left side locknut to 40-45 ft-lbs (54-61 Nm).

b. Verify that both alignment bars firmly contact the

Verify that belt deflection is within specification and that

rear wheel at two points. Use clamp or bungee

adjuster cams are tight against rear swingarm weld

cords to hold the bars in place. Tension should be

nubs. Holding weld nut on left side of axle, tighten cone

equal to avoid spreading or pinching the bars.

nut on right side to 95-105 ft-lbs (128.8-142.4 Nm).

c. Verify that the bars are straight by matching the

Remove seat. See Section 2.24 SEAT, REMOVAL.

width measurements at both ends.

Partially remove fuel tank to gain access to top engine

d. Straighten the front end and verify that the

mounting bracket and stabilizer link. See Section 4.7

measurements from the front wheel to the bar on

FUEL TANK (CARBURETED), PARTIAL REMOVAL,

one side of the motorcycle are equal at two points,

FLHT/C, or FLHR/S. For fuel injected models, see Sec-

both fore and aft.

tion

9.4 FUEL TANK (FUEL INJECTED), PARTIAL

REMOVAL, FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

e. Measure the front wheel to the bar on the other side

of the motorcycle, both fore and aft, and compare

Top Engine Mount:

the results to the measurements obtained under

a. On left side of motorcycle, tighten the two top

step 9(d). Measurements from left to right should be

engine mounting bracket to front and rear cylinder

equal +/- 0.030 inch (0.76 mm).

head bolts to 35-40 ft-lbs (48-54 Nm). See A of Fig-

ure 2-38.

Loosen jam nuts, and using the center hex, adjust

the front stabilizer link as required to obtain equal

b. Moving to right side of motorcycle, tighten the top

measurements at all four points (+/- 0.030 inch or

stabilizer link eyelet to frame weldment bolt to 18-22

0.76 mm). See Figure 2-39.

ft-lbs (24-30 Nm). See C of Figure 2-38.

c. Loosen both top stabilizer link jam nuts.

NOTE

d. Remove the top stabilizer link eyelet to top engine

After each adjustment, unload any binding of the front rubber

mounting bracket bolt. See B of Figure 2-38.

mount and verify that the alignment bars and front wheel are

Front Engine Mount:

still correctly positioned.

a. Remove flange locknuts from studs on lower frame

g. Holding the front stabilizer link adjuster and

crossmember. Remove voltage regulator from studs

mounting eyelets to prevent movement or binding,

and allow to hang by cables at front of motorcycle.

tighten both jam nuts.

b. Tighten two engine to front engine mounting bracket

bolts to 33-38 ft-lbs (45-52 Nm). See H of Figure 2-

h. Verify that the front rubber mount is centered under

38.

the thru bolt hole in the mounting plate.

2-30

2005 Touring: Chassis

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Chassis

To Correct:

Powertrain

Adjust front stablizer link.

To Correct:

Adjust top stablizer link.

FLT0239

FLT0240

Figure 2-39. Horizontally Misaligned

Figure 2-40. Vertically Misaligned

If the front rubber mount is centered and free of

a. Using the center hex to maintain equal thread

binding, proceed as follows:

engagement at both eyelets, adjust stabilizer link so

that bolt removed under step 7(d) threads in without

•

Tighten the two front engine mount to frame cross-

any stress or engine movement.

member bolts to 15-20 ft-lbs (20-27 Nm). See G of

Figure 2-38.

b. Tighten the stabilizer link eyelet to top engine

mounting bracket bolt to 18-22 ft-lbs (24-30 Nm).

•

Install center front engine mounting bracket to rub-

See B of Figure 2-38.

ber mount bolt (with washers and nut) and tighten to

15-20 ft-lbs (20-27 Nm). See F of Figure 2-38.

c. Holding the top stabilizer link adjuster and mounting

eyelets to prevent movement or binding, tighten

If centering or relaxation of the mount is required,

both jam nuts.

proceed as follows:

•

Loosen the two front engine mount to frame cross-

12.

Lower motorcycle to floor and remove hydraulic center

member bolts. See G of Figure 2-38.

stand or blocking.

13.

After verifying that the motorcycle is level, check vertical

•

Push on the rubber mount to center it with the thru

alignment placing an inclinometer on both front and rear

bolt hole in the mounting plate. It may be necessary

brake rotors. Front and rear lean angles should be equal

to bounce or wiggle the engine to unload any

+/-

1/2 degree. See Figure 2-40. If vertical alignment

binding of the rubber mount on the mounting plate.

exceeds specification, proceed as follows:

•

After the mount is centered, tighten the two front

a. Loosen the top stabilizer link eyelet to top engine

engine mount to frame crossmember bolts to 15-20

mounting bracket bolt. See B of Figure 2-38. Verify

ft-lbs (20-27 Nm). See G of Figure 2-38.

that bolt is unloaded and threads freely in and out of

the mounting bracket hole. If necessary, loosen jam

•

Install center front engine mounting bracket to rub-

nuts and adjust stabilizer link to a achieve a free

ber mount bolt (with washers and nut) and tighten to

15-20 ft-lbs (20-27 Nm). See F of Figure 2-38.

state. Tighten bolt to 18-22 ft-lbs (24-30 Nm) and

then tighten jam nuts before rechecking vertical

10.

Slide voltage regulator over studs on lower frame cross-

alignment.

member at front of vehicle. Install flange locknuts on

b. Look for components that are worn, damaged or out

studs and tighten to 70-100 in-lbs (7.9-11.3 Nm).

of specification. See INSPECTION on the next

11.

Adjust the top stabilizer link as follows:

page.

2005 Touring: Chassis

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14.

Remove the alignment bars from both the left and right

INSPECTION

side of the motorcycle.

15.

Snap the chrome plugs back into the rear swingarm

See Section

1.2 MAINTENANCE SCHEDULE for the

brackets.

required service interval. Perform inspection sooner if any

sag in the powertrain is observed or abnormal handling char-

16.

Install socket screw with lockwasher to fasten passenger

acteristics/vibrations are experienced.

footboard to rear swingarm bracket. Tighten screw to 15-

18 ft-lbs

(20-24 Nm). Repeat step on other side of

motorcycle.

Front Rubber Mount

17.

Install fuel tank. For carbureted models, see Section 4.7

FUEL TANK (CARBURETED), INSTALLATION (AFTER

Verify condition and torque of the mounting hardware.

PARTIAL REMOVAL), FLHT/C, or FLHR/S. For fuel

Visually inspect for wear, damage or improper installa-

injected models, see Section 9.4 FUEL TANK (FUEL

tion. Replace hardware as necessary.

INJECTED), INSTALLATION

(AFTER PARTIAL

Examine carefully at the bottom of the motorcycle paying

REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/S/I.

special attention to the area between the large flat metal

18.

Verify minimum clearance between the powertrain and

washer and the bracket on the frame. There should be a

the following frame mounted components:

gap between the mounting plate and the cushion portion

of the rubber mount.

a. Top Engine/Horn Mounting Bracket to Fuel Tank:

0.328 inch (8.3 mm).

Replace the rubber mount if there are any signs of

cracking or shearing.

b. Rocker Covers to Fuel Tank: 0.375 inch (9.5 mm).

c. Carburetor Top Cover to Fuel Tank: 0.375 inch (9.5

mm).

Rear Swingarm Mounts

d. Rear Spark Plug Boot to Fuel Valve: 0.250 inch (6.4

Verify condition and torque of the mounting hardware.

mm).

Visually inspect for wear, damage or improper installa-

e. Top Stabilizer Link to Induction Module: 0.375 inch

tion. Replace hardware as necessary.

(9.5 mm).

Examine rubber mount to be sure there is no twisting or

Front Stabilizer Link to Voltage Regulator: 0.375

binding at the parting line.

inch (9.5 mm).

g. Inner Primary Chaincase to Lower Frame Tube:

Engine Stabilizer Links

0.187 inch (4.8 mm).

Verify condition and torque of the mounting hardware.

h. Exhaust Crossover Pipe to Primary Housing: 0.125

Visually inspect for wear, damage or improper installa-

inch (3.2 mm).

tion. Replace hardware as necessary.

Tire to Rear Fender: 0.100 inch (2.5 mm).

Using flats machined into the stabilizer eyelet, gently

rock the link and check for separation of the molded-in

19.

Install seat. See Section 2.24 SEAT, INSTALLATION.

sleeve. Replace as necessary.

20.

Test ride the motorcycle.

Wear in the link also can be measured with a dial indica-

NOTE

tor by hand compressing and then releasing the link.

Replace any link that exceeds 0.025 inch (0.64 mm) of

Vehicle leads that require more than 2-lbs pull to correct

play or wear.

need further diagnosis. See INSPECTION on this page.

2-32

2005 Touring: Chassis

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FRONT BRAKE MASTER CYLINDER

2.10

GENERAL

f1284x2x

Dual Disc

Master cylinders designed for dual disc (two caliper) opera-

tion have an 11/16 inch bore, while those that are designed

for single disc (one caliper) operation have a 9/16 inch bore.

The bore size is stamped on the master cylinder assembly

inboard of the handlebar clamp bracket. See Figure 2-41.

1WARNING

Do not use a 9/16 inch bore master cylinder assembly on

Bore Size

dual disc (two caliper) models. Likewise, do not use an

Stamp

11/16 inch bore master cylinder assembly on single disc

(one caliper) models. These master cylinder assemblies

are not interchangeable. Using the wrong assembly can

adversely affect braking efficiency or result in brake fail-

ure, which could result in death or serious injury.

REMOVAL/DISASSEMBLY

Single Disc

CAUTION

Figure 2-41. Verify Correct Bore Size Before Use

Cover adjacent surfaces when removing, draining, filling

and/or bleeding brake system components. Spilling DOT

4 brake fluid on painted or other finished surfaces can

Remove the cardboard insert (or cable strap eyelet)

result in cosmetic damage. Immediately wipe up any

between the brake lever and lever bracket.

spilled brake fluid and thoroughly clean affected area

with water or 50/50 mix of water and denatured alcohol.

1WARNING

1. Remove banjo bolt and two steel/rubber washers to dis-

Always wear proper eye protection when removing re-

connect fitting of hydraulic brake line from master cylin-

taining rings. Use the correct retaining ring pliers. Verify

der housing. Hold suitable container under banjo bolt

that the tips of the pliers are not damaged or excessively

bore to allow reservoir to drain. Discard steel/rubber

worn. Slippage may propel the ring with enough force to

washers.

cause eye injury.

Remove retaining ring from pivot pin groove at bottom of

CAUTION

master cylinder bracket. Discard retaining ring.

Do not remove the master cylinder assembly without

Remove pivot pin and brake hand lever from master cyl-

first placing the

5/32 inch (4.0 mm) cardboard insert

inder assembly.

between the brake lever and lever bracket. Removal with-

out the insert may result in damage to the rubber boot

Carefully remove wiper with pick or similar tool.

and plunger of the Front Stoplight Switch.

Remove piston cap.

NOTE

Remove piston with O-ring and primary cup.

Use the eyelet of a small cable strap if the cardboard insert is

10. Remove spring.

not available.

2. Place the cardboard insert between the brake lever and

CAUTION

lever bracket. See Figure 2-42.

To prevent dirt and other contaminants from entering the

3. Using a T27 TORX drive head, remove two screws with

master cylinder reservoir, thoroughly clean the cover

flat washers to release handlebar clamp from the master

before removal.

cylinder housing. Remove the clamp and brake lever/

master cylinder assembly from the handlebar. See Fig-

11. Remove two Phillips screws, cover and cover gasket

ure 2-43.

from the master cylinder reservoir.

2005 Touring: Chassis

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5. Inspect the outlet port that mates with the brake line fit-

7959

ting. As a critical sealing surface, replace the housing if

any scratches, dents or other damage is noted.

6. Inspect the cover gasket for cuts, tears or general deteri-

oration. If gasket and/or sight glass replacement is nec-

essary, proceed as follows:

a. From inboard side, push sight glass toward top of

cover until free.

b. Pull rubber gasket from cover.

c. Fit nipple of new gasket into hole of cover aligning

gasket and cover thru holes.

d. From bottom of gasket, push flat end of sight glass

through nipple until top of glass is flush with top of

5/32 Inch

gasket. Verify that glass is square in bore. If some

(4.0 mm)

Cardboard

lubrication is necessary, use a small quantity of

Insert

clean brake fluid.

Figure 2-42. Install Cardboard Insert

ASSEMBLY/INSTALLATION

Before Removing Master Cylinder Assembly

Fit O-ring into groove on outboard side of piston (pin

side). See Figure 2-43.

CLEANING AND INSPECTION

Fit primary cup over lip on inboard side of piston, so that

closed side (smaller OD) contacts shoulder.

1WARNING

Coat piston bore of master cylinder reservoir with spe-

cial lubricant supplied in the service parts kit. Also apply

Do not use replacement parts from single caliper repair

the lubricant to OD of installed O-ring and primary cup.

kits (9/16 inch bore) on dual caliper models. Likewise, do

not use replacement parts from dual caliper repair kits

Insert metal retainer end of spring into piston bore, so

(11/16 inch bore) on single caliper models. Parts are not

that it seats against counterbore (recess) at bottom.

interchangeable. Using the wrong replacement parts can

Slide piston over spring.

adversely affect braking efficiency or result in brake fail-

ure, which could result in death or serious injury.

Fit wiper over piston cap so that flat side of wiper con-

tacts cap shoulder.

1. Always reassemble the master cylinder using new parts

from the correct repair kit.

Fit piston cap over piston pin.

2. Clean all parts with denatured alcohol or DOT 4 BRAKE

Press down on wiper until it contacts the counterbore.

FLUID. Do not contaminate with mineral oil or other sol-

Larger OD of wiper must be completely seated in groove

vents. Wipe dry with a clean, lint free cloth. Blow out

on outlet side of piston bore.

drilled passages and bore with a clean air supply. Do not

Note that the angular shape of the master cylinder cover

use a wire or similar instrument to clean drilled pas-

makes one side thicker than the other. Install the cover

sages in bottom of reservoir.

(with gasket) on the master cylinder reservoir, so that the

thicker side is positioned above the brake line fitting.

1WARNING

Install two Phillips screws to fasten cover to the reser-

voir, but do not tighten at this time.

Use denatured alcohol to clean brake system compo-

10.

Align hole in brake hand lever with hole in master cylin-

nents. Do not use mineral base solvents (such as gaso-

der bracket. From the top of the assembly, slide pivot pin

line and paint thinner) or deterioration of rubber parts

through bracket and hand lever.

may occur after assembly. Deterioration of components

may result in premature brake failure, which could result

in death or serious injury.

1WARNING

3. Carefully inspect all parts for wear or damage and

Always wear proper eye protection when installing re-

replace as necessary.

taining rings. Use the correct retaining ring pliers. Verify

4. Inspect the piston bore in the master cylinder housing for

that the tips of the pliers are not damaged or excessively

scoring, pitting or corrosion. Replace the housing if any

worn. Slippage may propel the ring with enough force to

of these conditions are found.

cause eye injury.

2-34

2005 Touring: Chassis

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Phillips

Screw

Provided in Service Parts Kit

Phillips

Screw

9/16 Inch Bore - HD Part No. 45006-96B

Site Glass

11/16 Inch Bore - HD Part No. 45072-96B

Cover

Gasket

Flat

T27 TORX

Washer

Screw

Master Cylinder

Reservoir

Pivot

Pin

Handlebar

Clamp

Brake Line

Seating Surface

Bushing

Spring

Primary

Cup

Piston

Metal

Retainer

O-Ring

Piston

Cap

Shoulder

O-Ring

Pin

Groove

Shoulder

Flat

Retaining

Side

Ring

Brake

Hand Lever

Wiper

Lubricant

f1866x2x

Figure 2-43. Front Brake Master Cylinder Assembly

2005 Touring: Chassis

2-35

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